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Michell Instruments XZR500ST User Manual

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XZR500ST
Oxygen Analyzer
User's Manual
97137 Issue 8
April 2017

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  • Page 1 XZR500ST Oxygen Analyzer User’s Manual 97137 Issue 8 April 2017...
  • Page 2 Please fi ll out the form(s) below for each instrument that has been purchased. Use this information when contacting Michell Instruments for service purposes. Analyzer Code Serial Number Invoice Date Location of Instrument Tag No Analyzer Code Serial Number Invoice Date...
  • Page 3 © 2017 Michell Instruments This document is the property of Michell Instruments Ltd. and may not be copied or otherwise reproduced, communicated in any way to third parties, nor stored in any Data Processing System without the express written authorization of Michell Instruments Ltd.

  • Page 4: Table Of Contents

    XZR500 User’s Manual Contents Safety ..........................vii Electrical Safety ......................vii Pressure Safety ......................vii Temperature ....................... vii Toxic Materials ......................vii Repair and Maintenance ....................vii Calibration ........................vii Safety Conformity ....................... vii Abbreviations ........................viii Warnings .......................... viii INTRODUCTION ....................1 System Description .....................
  • Page 5 Enclosure for Controlling the Ejector Heating - General Wiring Diagram ..56 Figure 23 XZR500 Flange and Back Flange (Optional) ..........59 Figure 24 Insulators (Flange and Rear Sealing Screw) ..........59 Figure 25 Mounting Plate Dimensions ...............60 Figure 26 Wiring of the Second 4-20 mA Output ............62 Michell Instruments...
  • Page 6 XZR500 User’s Manual Tables Table 1 Control Keys....................5 Table 2 Maximum Temperature of Gases ..............7 Table 3 Cable Specifi cations .................. 13 Table 4 Connection of the Control Unit..............13 Table 5 Access codes 0.12 & 0.20 ................. 21 Table 6 Alarm Set-Point Examples .................

  • Page 7: Safety

    Repair and Maintenance The instrument must be maintained either by the manufacturer or an accredited service agent. Refer to www.michell.com for details of Michell Instruments’ worldwide offi ces contact information. Calibration The recommended calibration interval for the analyzer is 6 to 12 months depending on the application in which the instrument is used.

  • Page 8: Abbreviations

    XZR500 User’s Manual Abbreviations The following abbreviations are used in this manual: alternating current Ampere °C degrees Celsius °F degrees Fahrenheit hertz kilogram(s) l/hour liters per hour milli Ampere mbars millibars millimeter(s) parts per million Temperature Volt Watts Warnings The following general warnings listed below are applicable to this instrument. They are repeated in the text in the appropriate locations.

  • Page 9: Introduction

    System Description 1.1.1 Measurement Principle Michell Instruments’ aim is to provide the best measurement solutions for any given industrial process or laboratory application. In the case of oxygen control and measurement we have developed a highly advanced and miniaturized oxygen sensor, the MSRS.

  • Page 10: The Msrs

    XZR500 User’s Manual INTRODUCTION By setting the oxygen reference pressure and measuring voltage E and temperature T, you can deduce the oxygen partial pressure you want to measure. The volumetric concentration (expressed here in O %vol.) is determined by the ratio between the oxygen partial pressure (Ppmeas) and the atmospheric pressure (Ptot).

  • Page 11: General Remarks

    Inter-tubes gasket M8 spacer Gasket for plug Gasket for sealing screw CHC 6x25 screw for fi xing Big rear nut XZR500 sensor attachmt plate TRF 3x16 screw for connector Inter-tube gasket XZR500 Sensor Head & Probe Figure 4 Michell Instruments...

  • Page 12: Control Unit

    The whole set is mounted on the stack with a steel fl ange which is welded on the XZR500 outer tube. Michell Instruments can provide an optional mounting kit containing a counter fl ange with threaded rods (if needed please refer to Appendix G).

  • Page 13: Figure 7 Control Unit

    The cable connecting the control unit and the probe supplies the furnace with power and it relays the MSRS temperature and voltage measurements to the Control Unit. The standard cable length is 6 meters long (optional, up to 100 meters). Michell Instruments...

  • Page 14: Specifi Cations

    XZR500 User’s Manual INTRODUCTION Specifi cations 1.3.1 General • Microcontroller: Motorola 68HC12 • Inlet converter: analog, 16 bits resolution, 0.0015% linearity error, with fi lter and embedded calibrator • Outlet converter: analog, 12 bits resolution, ±1 bit linearity error • Display resolution: 0.1% O (or 0.01 % on request and during calibration)

  • Page 15: Table 2 Maximum Temperature Of Gases

    XZR500 /HC Hastelloy C2000 Tmax = 600°C and corrosive gases XZR500 /CC Ceramic Tmax = 1300°C XZR500 /HL Halar coating Tmax = 150°C Table 2 Maximum Temperature of Gases • Minimum speed of the sample gases: 0.5 m/s Michell Instruments...

  • Page 16: Optional Equipment

    XZR500 User’s Manual INTRODUCTION 1.3.2 Optional Equipment • Tubular counter-fl ange for fi xing the probe to the stack (see Appendix G) • Flange insulation (to prevent condensation forming) • Extra length of cable (up to 100 meters) • Calibration and verifi cation kit •...

  • Page 17: Installation

    Excessive vibrations must be avoided as ceramic is a brittle material. Incorrect handling or placement of the probe will invalidate the warranty. Michell Instruments...

  • Page 18: Probe Mechanical Installation

    XZR500 User’s Manual INSTALLATION Probe Mechanical Installation e. Probe head g. Gasket for locking ring 3 marks to indicate h. Locking ring d. Gasket for flange b. Gasket for flange the bevelled edge c. Outer tube f. Inner probe tube a.

  • Page 19: Figure 10 Flange Gasket Orientation

    fl ange of the probe head together by secure nuts onto four bolts on the counter fl ange. e. Probe head d. Gasket for flange b. Gasket for flange a. Tubular counter flange Tubular Counter Flange Position Figure 11 Michell Instruments...

  • Page 20: Figure 12 Inner Tube Orientation

    XZR500 User’s Manual INSTALLATION Place the gasket onto the inner tube (f) and insert into the probe head (e) (see Figure 8). Make sure the bevelled edge of the inner tube tip faces the opposite direction to the gas inlet hole on the outer tube (c) as shown below.

  • Page 21: Control Unit Mechanical Installation

    J5 Right connector: power and alarms CABLE (supplied) Table 4 Connection of the Control Unit Both the ground wire of the supplied cable and the earth wire from the mains must be connected to the copper bar near the cable gland. Michell Instruments...

  • Page 22: 2.4.2.1 Connection To The Mains

    XZR500 User’s Manual INSTALLATION 2.4.2.1 Connection to the Mains Use shielded cable (2 x 1.5mm² max.) that is terminated appropriately. Follow the Table 4 wiring diagram (pins 48, 49 and 50). Connect both the screen and the earth wire to the copper bar near the cable gland. 2.4.2.2 Connection of the 0/4-20 Output We suggest that shielded cable (2 x 0.75mm²) is used and terminated appropriately.

  • Page 23: Figure 14 Probe Wiring Diagram

    XZR500 User’s Manual INSTALLATION Connect the end of the cable - using the end with 6 wires - according to the Figure 14 wiring diagram. MSRS Furnace probe Ref. connector Supplied Cable Figure 14 Probe Wiring Diagram Michell Instruments...

  • Page 24: Operation

    XZR500 User’s Manual OPERATION OPERATION The MSRS is a fragile element - keep the sensor free from any shock. Any measurements that need to be done at the MSRS terminals must be done very carefully in order to prevent irreversible damage to the sensor. NEVER attempt to measure the resistance between the MSRS reference terminal and another terminal Use a voltmeter with impedance >1000 MΩ...

  • Page 25: Start-Up

    When the temperature is within 30°C of the required temperature (after about 15 minutes), the system calculates the oxygen concentration and the result will appear on the display. O2 Concentration Then the following default message appears: xx.xx % Michell Instruments...

  • Page 26: Display, Confi Guration And Adjustment

    XZR500 User’s Manual OPERATION Display, Confi guration and Adjustment During confi guration there is no data communication between the Control Unit and the Sensor Head and this could disturb the stability of the furnace temperature. Make sure that the furnace temperature is stable before confi...
  • Page 27 Press and hold the [*] key to re- Enter Your selection? enter the main selection menu Visu * Cal + Set - Press the [*] key from the main Enter Cell voltage selection menu show fourth parameter: Cell voltage xx.xx mV Michell Instruments...
  • Page 28 XZR500 User’s Manual OPERATION Press and hold the [*] key to re- Enter Your selection? enter the main selection menu Visu * Cal + Set - Press the [*] key from the main Enter Absolute pressure selection menu to show the fi fth parameter: Absolute pressure xxxx.x mBar Repeating the process again will return...

  • Page 29: Set-Up [ - ]

    Sets the offset pressure. Do not change Offset pressure Pre-set mbar without consulting factory Absolute Sets the absolute pressure. Do not change Pre-set mbar pressure without consulting factory Cell cleaning Start the cell self-cleaning process Table 5 Access codes 0.12 & 0.20 Michell Instruments...

  • Page 30: 3.3.2.1 Access Code 0.12 - Quick Settings

    XZR500 User’s Manual OPERATION 3.3.2.1 Access code 0.12 - quick settings From the main menu page, press and hold the Your selection? key until the main selection menu Enter appears. Visu * Cal + Set - Press the [–] (Set-up menu) from the main Access code? selection menu to show the Access code page.

  • Page 31: Table 6 Alarm Set-Point Examples

    600ppm represents 0.24% logarithmic. The desired alarm is /250,000ppm = 0.24 of the range at 600 ppm. Table 6 Alarm Set-Point Examples Alarm 2 To confi gure Alarm 2, repeat steps 1 and 2 as shown in Alarm 1. Michell Instruments...

  • Page 32: 3.3.2.2 Access Code 0.20 - Advanced Settings

    XZR500 User’s Manual OPERATION Alarm hysteresis This page shows the value for the relay hysteresis Relay hysteresis that is expressed in percentage oxygen. Press the [+] and [–] keys to adjust the value. Press 0.10 the [*] key to confi rm the selection and Enter move to the next parameter.
  • Page 33 If the analyzer display is 20.4% HA = ((20.9 - 20.4) / 20.4) * 100 = 2.5 Press the [+] and [–] keys to adjust the value. Press the [*] key to confi rm the selection Enter and move to the next parameter. Michell Instruments...
  • Page 34 XZR500 User’s Manual OPERATION Output Signal This page shows the available current ranges 0 or 4-20 mA for the signal output. Enter 0.00 for 0-20 mA and 4.00 for 4-20 mA. Press the [+] and [–] 4.00 keys to adjust the value. Press the [*] Enter key to confi...
  • Page 35 This page displays the absolute pressure. Abs. pressure The value is factory pre-set and may vary for individual analyzers. 11.00 CAUTION: Do not change the value without consulting the factory. Press the [*] key to move to the next Enter parameter. Michell Instruments...
  • Page 36 XZR500 User’s Manual OPERATION Cell self-cleaning This function allows the analyzer to self-clean Cleaning cell the sensor cell. The cleaning process lasts for one hour. The furnace is heated to 780°C in 0.00 order to clean itself and the MSRS. Remove the inner probe tube to make the self-cleaning more effi...

  • Page 37: Calibration [+]

    NOTE: Tighten up the stainless steel locking nut by hand and then tighten again using a 7/16" spanner, for 1/8th turn so as not to damage the connection. NOTE: During calibration the output signal is frozen at the last value measured before the beginning of the calibration procedure. Michell Instruments...

  • Page 38: 3.3.3.3 Calibration Procedure

    XZR500 User’s Manual OPERATION 3.3.3.3 Calibration Procedure Follow Sections 3.3.3.1 and 3.3.3.2 to connect the calibration gas to the analyzer (8% oxygen bottle, if 1G or 2G is ordered). Do not switch on the calibration gas fl ow at this time.
  • Page 39 Yes* No - with the real oxygen content of the control gas. [*] key – Ends the verifi cation process and moves to the next page [–] key – No effect Michell Instruments...
  • Page 40 XZR500 User’s Manual OPERATION Once the verifi cation step is completed Stop gas? or skipped, the screen shows ‘Stop gas?’ to remind the user to switch off the Yes * No - calibration/control gas. Confi rm the fi nish of the calibration with the [*] key and move to next page.

  • Page 41: Figure 15 Calibration Flow-Chart

    Yes * No - Stop gas? No effect Yes * No - Purge sequence lasts 3 minutes but it can be stopped Adjustment sequence after 1 minute by pressing the [*] key Purge running/Value 02 concentration xx.x(x)% Calibration Flow-Chart Figure 15 Michell Instruments...

  • Page 42: Maintenance

    XZR500 User’s Manual MAINTENANCE MAINTENANCE Preventative Maintenance - Cleaning The XZR500 should be periodically cleaned. The frequency of cleaning will depend upon your application. • Identify the 3 orientation marks on the inner tube and remove it ( Figure 4 (23)). •...

  • Page 43: Replacement Of The Xzr500 Msrs

    Power up the analyzer. • Wait for one hour. • Re-fi t the probe inner tube. • Set self-cleaning (0.10 code). • Wait for few hours before calibrating the analyzer (see Section 3.3.3). XZR500 MSRS Mounting Diagram Figure 16 Michell Instruments...

  • Page 44: Figure 17 Xzr500 Top View

    XZR500 User’s Manual MAINTENANCE Figure 17 XZR500 Top View Figure 18 XZR500 Side View 97137 Issue 8, April 2017...

  • Page 45: Replacement Of The Furnace

    Replace the cover. • Power up the analyzer. • Wait for one hour. • Re-fi t the probe inner tube. • Set self-cleaning (0.10 code). • Wait for a few hours before calibrating the analyzer (see Section 3.3.3). Michell Instruments...

  • Page 46: Replacement Of The Xzr500 Microcontroller Card

    XZR500 User’s Manual MAINTENANCE Replacement of the XZR500 Microcontroller Card While the power is on, note down the values of all the parameters (see Section 3.3.2). All settings and parameters will be lost when the faulty microcontroller card is changed. Turn off the power and disconnect the lead from the mains.

  • Page 47: Error Messages

    Check the thermocouple threads to make sure they are not short-circuiting. • If the red LED (heating indicator) is lit continuously, the furnace is under- powered. Verify the analyzer’s power supply voltage. • Faulty furnace. Michell Instruments...
  • Page 48 XZR500 User’s Manual MAINTENANCE Calibration fault Calibration error. Probable cause(s): • The calibration gas value that was stated in the parameter’s sequence in Access Code 0.12 does not correspond to the actual calibration gas value. Press RESET ( Figure 7) or check that the test gas value in Access Code 0.12 is the same as the actual calibration gas value (refer to Section 3.3.2.1).

  • Page 49: Spare Parts

    XZR500-209154 Gasket for XZR500 fl ange (x10) XZR500-108002 Gasket for XZR500 wheel XZR500-209143 Inner Tube Gaskets (x10) XZR500-209144 Rear Nut Gaskets (x10) XZR500-104003 XZR500 Cable (per meter) XZR500-203006 XZR500 furnace XZR500-109015 SS bulkhead union XZR500-109004 1/8’’ SS plug Michell Instruments...
  • Page 50 XZR500 User’s Manual APPENDIX A Appendix A Technical Specifi cations 97137 Issue 8, April 2017...

  • Page 51: Appendix A Technical Specifi Cations

    (Maximum temperature) C2000 (600°C) (1112°F) Halar coating (120°C) (248°F) Ceramic (1300°C) (2372°F) Probe Lengths 0.4, 0.6 and 0.9m (15.75, 23.62, 35.43”) Installation Stack and wall mounting Weather proof enclosure to sensor: IP53 Housing Ingress Protection Control unit: IP52 Michell Instruments...
  • Page 52 XZR500 User’s Manual APPENDIX B Appendix B Confi guration for the RS232 Port (Optional) 97137 Issue 8, April 2017...

  • Page 53: Appendix B Confi Guration For The Rs232 Port (Optional)

    The wiring cable should be equipped with 2 DB9 female plugs and connected as follows: • pin 2 pin 2 • pin 3 pin 3 • pin 5 pin 5 • strap 7-8 strap 7-8 Commands: corresponds to the spacing bar corresponds to the return key  Michell Instruments...
  • Page 54 XZR500 User’s Manual APPENDIX B Mnemonic ASCII Value concentration XX.XX or _OXY X.XXE XX _TEM Furnace temperature XXX.XX MSRS voltage _UMV XXX.XX _ANV Ambient temperature XX.XX _ALR K1, K2, K3 Relay status K1 + K2 + K3 = from 0 to 7 Sets self-calibration after 10 minutes bleed RECEIPT _CAL...

  • Page 55: Appendix C Calculation Of Co

    XZR500 User’s Manual APPENDIX C Appendix C Calculation of CO Michell Instruments...
  • Page 56 XZR500 User’s Manual APPENDIX C Appendix C Calculation of CO The formula below shows how to calculate CO knowing the oxygen content and the fuel burned: = K2 * (20.9-O )/20.9 where K2 is absolute max CO Set K2 factor in Access code 0.20, pressing the + and - keys, i.e., for coal, capture 18.39.
  • Page 57 XZR500 User’s Manual APPENDIX D Appendix D XZR500 Sensor Head and Probe General Dimensions Michell Instruments...

  • Page 58: Figure 19 Xzr500 Sensor Head & Probe General Dimensions

    XZR500 User’s Manual APPENDIX D Appendix D XZR500 Sensor Head and Probe General Dimensions 133mm (5.24”) 97mm (3.82”) X = 400, 600 or 900mm 260mm (10.24”) XZR500 Sensor Head & Probe General Dimensions Figure 19 Outer Tube Dimensions Inner Tube Dimensions Probe Version Outer Diameter x Wall Thickness Outer Diameter x Wall Thickness...
  • Page 59 APPENDIX E XZR500 User’s Manual Appendix E Back Flushing System (Optional) Michell Instruments...

  • Page 60: Figure 20 Position Of The Probe

    XZR500 User’s Manual APPENDIX E Appendix E Back Flushing System (optional) The pressurized probe cleaning system comprises: • A steel housing containing electronics and a connector block. • A CD Rom for programming the automaton. • An electro-valve with a connection to place on the back of the probe, in place of the sealing screw, a cable (standard length = 6 meters) for connecting the electro-valve.
  • Page 61 3 & 4: wiring of electro-valve • terminals 5 & 6: to connect with terminals 37 and 38 in the Control Unit To modify the monitoring sequence of the fl ushing system, please refer to the manual supplied with the automaton. Michell Instruments...
  • Page 62 APPENDIX F XZR500 User’s Manual Appendix F Heated Flue Gas Ejection System (Optional) 97137 Issue 8, April 2017...

  • Page 63: Figure 21 Installation Of The Ejector/Heating System

    • A compressed air connecting system • Michell Instruments does not supply the system for cleaning the compressed air and regulating the inlet pressure: the pressure regulator should supply pressure between 0 and 3 bar. Supply of compressed air...

  • Page 64: Figure 22 Enclosure For Controlling The Ejector Heating - General Wiring Diagram

    APPENDIX F XZR500 User’s Manual 1.5mm Brown 1.5mm Blue 1.5mm Blue 1.5mm Brown 1.5mm 1.5mm Blue Brown Regulator CB100 11 12 Compensated cable TC-K 1.5mm Brown Connector TC-K To the heating insulator 230V/6A Supply Enclosure for Controlling the Ejector Heating - General Wiring Diagram Figure 22 Confi...
  • Page 65 In order to optimize the installation and reduce the risk of clogging, mount the probe on a small fl ange. We recommend Michell Instruments’ optional counter-fl ange - see Appendix G). Provide proper insulation for both the fl ange and the ejector.
  • Page 66 APPENDIX G XZR500 User’s Manual Appendix G Mounting Options 97137 Issue 8, April 2017...

  • Page 67: Figure 23 Xzr500 Flange And Back Flange (Optional)

    MADE OF TWO HALF-SHELLS ALUMINUM PROTECTIVE COVER (ISOXAL 8/10) A.A. Ø185mm 175mm Ø85±2 CLOSED INSULATOR GLASS WOOL (PS1713 ISOVER) Aluminum protective cover (ISOXAL 8/10) A.A. 110mm Glass wool PS1713 (ISOVER) Insulators (Flange and Rear Sealing Screw) Figure 24 Michell Instruments...

  • Page 68: Figure 25 Mounting Plate Dimensions

    APPENDIX G XZR500 User’s Manual Mounting Plate Dimensions 100cm (39.3”) 4cm (1.6”) 30cm (11.8”) 45° 45° ø40 (x4 at 90°) ø55 Figure 25 Mounting Plate Dimensions 97137 Issue 8, April 2017...
  • Page 69 APPENDIX H XZR500 User’s Manual Appendix H Second 4-20mA Output Michell Instruments...

  • Page 70: Figure 26 Wiring Of The Second 4-20 Ma Output

    APPENDIX H XZR500 User’s Manual Appendix H Second 4-20 mA Output The optional 2nd analog output allows acquisition of a linear 4-20 mA current corresponding to the 0.1% - 25% scale (this scale cannot be changed). This 4-20 mA output is galvanic isolated (500 V). Wiring of the 2nd 4-20 mA output on the connector (on the electronic card) is as follows: •...
  • Page 71 APPENDIX I XZR500 User’s Manual Appendix I Automatic Calibration (Optional) Michell Instruments...

  • Page 72: Appendix I Automatic Calibration (Optional)

    APPENDIX I XZR500 User’s Manual Appendix I Automatic Calibration (Optional) The analyzer can be automatically calibrated, if this function has been purchased, and can be as simple as pressing a button to start up the sequence. This assumes that the calibration gas is connected permanently and the cal gas value is properly confi...
  • Page 73 APPENDIX J XZR500 User’s Manual Appendix J Quality, Recycling & Warranty Information Michell Instruments...

  • Page 74: Appendix J Quality, Recycling & Warranty Information

    XZR500 User’s Manual Appendix J Quality, Recycling & Warranty Information Michell Instruments is dedicated to complying to all relevant legislation and directives. Full information can be found on our website at: www.michell.com/compliance This page contains information on the following directives: •...
  • Page 75 APPENDIX K XZR500 User’s Manual Appendix K Return Document & Decontamination Declaration Michell Instruments...

  • Page 76: Appendix K Return Document & Decontamination Declaration

    Has the equipment been cleaned and decontaminated? NOT NECESSARY Michell Instruments will not accept instruments that have been exposed to toxins, radio-activity or bio-hazardous Work will not be carried out on any unit that does not have a completed decontamination declaration.
  • Page 78 http://www.michell.com...

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